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Abstract
A non-contact method, using magnetic drag force principle, was proposed
to design the braking systems to improve the shortcomings of the conventional
braking systems. The extensive literature detailing all aspects of the magnetic
braking is briefly reviewed, however little of this refers specifically to upright
magnetic braking system, which is useful for industries. One of the major issues to
design upright magnetic system is to find out the magnetic flux. The changing
magnetic flux induces eddy currents in the conductor. These currents dissipate
energy in the conductor and generate drag force to slow down the motion. Therefore,
a finite element model is developed to analyze the phenomena of magnetic flux
density when air gap and materials of track are varied. The verification shows the
predicted magnetic flux is within acceptable range with the measured value. The
results will facilitate the design of magnetic braking systems.
Isometric view
Top view
Materials
36 Gauge Magnet wire ,
AC Motor ,
Sprint ,
Iron Stand,
Wheel
Description:
The disc brake or disk brake is a device for slowing or stopping the rotation of
a wheel. A brake disc usually made of cast iron or ceramic composites is
connected to the wheel and the axle. To stop the wheel, friction material in
the form of brake pads is forced mechanically, hydraulically, pneumatically
or electromagnetically against both sides of the disc. Friction causes the disc
and attached wheel to slow or stop. But in our project hydraulic energy is
used as the source of power, due to high applied force and torque
2. General Principle of Brake System
Moving things have kinetic energy and, if you want to stop them, you have to
get rid of that energy somehow. If you're on a bicycle going fairly slowly, you
can simply put your feet down so they drag on the ground. The soles of your
feet act as brakes. Friction (rubbing) between the rough ground and the grip
on your soles slows you down, converting your kinetic energy into heat energy
(do it long enough and your shoes will get hot). Brakes on vehicles work pretty
much the same way, with "shoes" that press rubber pads (brake blocks)
against discs mounted to the wheels. (Find out more about this in our main
article on brakes.) Even if you make brakes from super-strong, hard-wearing
materials like Kevlar®, they're still going to wear out sooner or later. But there
are other problems with friction brakes. The faster you go, the harder they
have to work to get rid of your kinetic energy, and the quicker they'll wear
out. Use your brakes too often and you may suffer a problem called brake
fade, where heat builds up too much in the brakes or the hydraulic system
that operates them and the brakes can no longer work as effectively. What if
your brakes can't stop you in time?
The conventional friction brake can absorb and convert enormous energy
values (25h.p. without self-destruction for an 5-axle truck, Reverdin1974),
but only if the temperature rise of the friction contact materials is controlled.
This high energy conversion therefore demands an appropriate rate of heat
dissipation if a reasonable temperature and performance stability are to be
maintained. Unfortunately, design, construction, and location features all
severely limit the heat dissipation function of the friction brake to short and
intermittent periods of application. This could lead to a ‘brake fade’ problem
(reduction of the coefficient of friction, less friction force generated) due to
the high temperature caused by heavy brake demands. The main reasons why
conventional friction brakes fail to dissipate heat rapidly are as follows:
- poor ventilation due to encapsulation in the road wheels,
- diameter restriction due to tire dimensions,
- width restrictions imposed by the vehicle spring designer;
- problems of drum distortion at widely varying temperatures.
The working principle of the electric retarder is based on the creation of eddy
currents within a metal disc rotating between two electromagnets, which sets
up a force opposing the rotation of the disc . If the electromagnet is not
energized, the rotation of the disc is free and accelerates uniformly under the
action of the weight to which its shaft is connected. When the electromagnet
is energized, the rotation of the disc is retarded and the energy absorbed
appears as heating of the disc. If the current exciting the electromagnet is
varied by a rheostat, the braking torque varies in direct proportion to the value
of the current. It was the Frenchman Raoul Sarazin who made the first vehicle
application of eddy current brakes. The development of this invention began
when the French company Telma, associated with Raoul
Sarazin, developed and marketed several generations of electric brakes based
on the functioning principles described above . A typical retarder consists of
stator and rotor. The stator holds 16 induction coils, energized separately in
groups of four. The coils are made up of varnished aluminum wire mounded
in epoxy resin. . The rotor is made up of two discs, which provide the braking
force. when subject to the electromagnetic influence when the coils are
excited. Careful design of the fins, which are integral to the disc, permit
independent cooling of the arrangement.
9. Electric Control System
Features:-
Technical Features:
Coil Voltage: 24 V
Torque: 3 N-m to 3600 N-m
Compact design
Electromagnetic brakes are provided
With or without outer carrier, jaw and driver
With inner & outer multiple discs.
Power off brakes stop or hold a load when electrical power is either
accidentally lost or intentionally disconnected. In the past, some
companies have referred to these as "fail safe" brakes. These brakes are
typically used on or near an electric motor. Typical applications include
robotics, holding brakes for Z axis ball screws and servo motor brakes.
Brakes are available in multiple voltages and can have either standard
backlash or zero backlash hubs. Multiple disks can also be used to
increase brake torque, without increasing brake diameter. There are 2
main types of holding brakes. The first is spring applied brakes. The
second is permanent magnet brakes.
(5)Particle brake
Magnetic particle brakes are unique in their design from other electro-
mechanical brakes because of the wide operating torque range available.
Like an electro-mechanical brake, torque to voltage is almost linear;
however, in a magnetic particle brake, torque can be controlled very
accurately (within the operating RPM range of the unit). This makes these
units ideally suited for tension control applications, such as wire winding,
foil, film, and tape tension control. Because of their fast response, they
can also be used in high cycle applications, such as magnetic card readers,
sorting machines and labeling equipment.
Magnetic particles (very similar to iron filings) are located in the powder
cavity. When electricity is applied to the coil, the resulting magnetic flux
tries to bind the particles together, almost like a magnetic particle slush.
As the electric current is increased, the binding of the particles becomes
stronger. The brake rotor passes through these bound particles. The output
of the housing is rigidly attached to some portion of the machine. As the
particles start to bind together, a resistant force is created on the rotor,
slowing, and eventually stopping the output shaft.
When electricity is removed from the brake, the input is free to turn with
the shaft. Since magnetic particle powder is in the cavity, all magnetic
particle units have some type of minimum drag associated with them.
When electricity is removed from the brake, the hysteresis disk is free to
turn, and no relative force is transmitted between either member.
Therefore, the only torque seen between the input and the output is
bearing drag.
(7)Multiple disk brake
Multiple disk brakes are used to deliver extremely high torque within a
small space. These brakes can be used either wet or dry, which makes
them ideal to run in multi-speed gear box applications, machine tool
applications, or in off road equipment.
When electricity is removed from the brake, the armature is free to turn
with the shaft. Springs keep the friction disk and armature away from each
other. There is no contact between braking surfaces and minimal drag.
12-Thermal Dynamics-
where:
M = Mass of air circulated;
Cp = Calorific value of air;
= Difference in temperature between the air entering and the air leaving
the fan;
The electromagnetic brakes has excellent heat dissipation efficiency owing to
the high temperature of the surface of the disc which is being cooled and also
because the flow of air through the centrifugal fan is very rapid. Therefore,
the curie temperature of the disc material could never been reached .The
practical location of the electromagnetic brakes prevents the direct
impingement of air on the brakes caused by the motion of the vehicle. Any air
flow movement within the chassis of the vehicle is found to have a relatively
12 insignificant effect on the air flow and hence temperature of both front and
rear discs. Due to its special mounting location and heat dissipation
mechanism, electromagnetic brakes have better thermal dynamic
performance than regular friction brakes.
13-MERITS-
Quick operation
Accuracy is more.
It reduces the manual effort.
In electromagnetic braking system maintenance is very less.
electromagnetic braking system work is done very fast, because of
electronic component. And flowing of current is very fast.
Very less effort is required to apply the brake.‡
It is reasonable as compare with other brakes.
14-DERMIRTS-
With all the advantages of electromagnetic brakes over friction brakes, they
have been widely used on heavy vehicles where the ‘brake fading’ problem is
serious. The same concept is being developed for application on lighter
vehicles.